Patent Application
20180171540
The present disclosure relates to fabrics and garments, and in particular to fabrics and garments that are laser-treated to improve their properties.
The face side of fabric (i.e., the side facing away from the wearer of a garment incorporating the fabric) has been treated with a high wavelength laser to provide aesthetic features to the fabric, including patterns and designs. For example, denim jeans have been treated with a laser to give the jeans an aged or “vintage” appearance. The laser treatments affect the fabric at the fiber level.
In addition, many fabrics are treated with chemical additives to provide the fabric with desirable properties or to improve existing fabric properties. For example, it has been known to coat fabrics with silver to provide antimicrobial resistance, with titanium dioxide for ultraviolet protection, and with zinc peroxide to provide antistatic properties. Chemical coatings have a tendency to wash out of the fabric during laundering, however.
These and other shortcomings are addressed by aspects of the present disclosure.
In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
Aspects of the disclosure relate to a laser-treated fabric having a body side and a face side, comprising: a plurality of pores located on at least some fibers on at least the body side of the fabric; and at least one chemical additive embedded within or anchored to the plurality of pores. The pores have a pore size of from about 1 nm to about 20 μm.
Further aspects of the disclosure relate to a garment comprising a laser-treated fabric, the laser-treated fabric having a body side and a face side and comprising: a plurality of pores located on at least some fibers on at least the body side of the fabric; and at least one chemical additive embedded within or anchored to the plurality of pores. The pores have a pore size of from about 1 nm to about 20 μm.
Certain aspects of the disclosure relate to a method for treating a fabric, the fabric having a body side and a face side, the method comprising: applying a laser treatment to at least the body side of the fabric to form a plurality of pores on fibers of at least the body side of the fabric; and applying at least one chemical additive to the fabric such that the at least one chemical additive is embedded within or anchored to the plurality of pores. The pores have a pore size of from about 1 nm to about 20 μm.
The present disclosure can be understood more readily by reference to the following detailed description of the disclosure and the Examples included therein. In various aspects, the present disclosure pertains to methods for treating a fabric. The fabric has a body side and a face side. The method includes applying a laser treatment to at least the body side of the fabric. The laser treatment forms a plurality of pores on fibers of at least the body side of the fabric. The method further includes applying at least one chemical additive to the fabric such that the at least one chemical additive is embedded within or anchored to the plurality of pores. The pores have a pore size of from about 1 nm to about 20 μm. In some aspects a curing treatment is optionally applied to the fabric to cure the at least one chemical additive. Aspects of the disclosure further relate to laser-treated fabrics and garments including the laser-treated fabrics.
Before the present compounds, compositions, articles, systems, devices, and/or methods are disclosed and described, it is to be understood that they are not limited to specific synthetic methods unless otherwise specified, or to particular reagents unless otherwise specified, as such can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting.
Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.
Moreover, it is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of embodiments described in the specification.
All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.
It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” can include the embodiments “consisting of” and “consisting essentially of” Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.
As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a chemical additive” includes mixtures of two or more chemical additives.
As used herein, the term “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.
Ranges can be expressed herein as from one value (first value) to another value (second value). When such a range is expressed, the range includes in some aspects one or both of the first value and the second value. Similarly, when values are expressed as approximations, by use of the antecedent ‘about,’ it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.
As used herein, the terms “about” and “at or about” mean that the amount or value in question can be the designated value, approximately the designated value, or about the same as the designated value. It is generally understood, as used herein, that it is the nominal value indicated ±10% variation unless otherwise indicated or inferred. The term is intended to convey that similar values promote equivalent results or effects recited in the claims. That is, it is understood that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but can be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. In general, an amount, size, formulation, parameter or other quantity or characteristic is “about” or “approximate” whether or not expressly stated to be such. It is understood that where “about” is used before a quantitative value, the parameter also includes the specific quantitative value itself, unless specifically stated otherwise.
As used herein, the terms “optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. For example, the phrase “optional curing treatment” means that the curing treatment may or may not be applied and that the description includes fabrics to which the curing treatment has been applied and also fabrics that have not been subjected to a curing treatment.
As used herein, the term “effective amount” refers to an amount that is sufficient to achieve the desired modification of a physical property of the composition or material. For example, an “effective amount” of a curing additive refers to an amount that is sufficient to achieve the desired improvement in the property modulated by the formulation component, e.g., achieving the desired level of curing. The specific level in terms of wt % in a composition required as an effective amount will depend upon a variety of factors including, but not limited to, the fabric and chemical additive selected and the end use of the fabric or garment.
Disclosed are the components to be used to prepare the compositions of the disclosure as well as the compositions themselves to be used within the methods disclosed herein. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed and a number of modifications that can be made to a number of molecules including the compounds are discussed, specifically contemplated is each and every combination and permutation of the compound and the modifications that are possible unless specifically indicated to the contrary. Thus, if a class of molecules A, B, and C are disclosed as well as a class of molecules D, E, and F and an example of a combination molecule, A-D is disclosed, then even if each is not individually recited each is individually and collectively contemplated meaning combinations, A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any subset or combination of these is also disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E would be considered disclosed. This concept applies to all aspects of this application including, but not limited to, steps in methods of making and using the compositions of the disclosure. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific aspect or combination of aspects of the methods of the disclosure.
References in the specification and concluding claims to parts by weight of a particular element or component in a composition or article, denotes the weight relationship between the element or component and any other elements or components in the composition or article for which a part by weight is expressed. Thus, in a compound containing 2 parts by weight of component X and 5 parts by weight component Y, X and Y are present at a weight ratio of 2:5, and are present in such ratio regardless of whether additional components are contained in the compound.
A weight percent of a component, unless specifically stated to the contrary, is based on the total weight of the formulation or composition in which the component is included.
As used herein the terms “weight percent,” “wt %,” and “wt. %,” which can be used interchangeably, indicate the percent by weight of a given component based on the total weight of the composition, unless otherwise specified. That is, unless otherwise specified, all wt % values are based on the total weight of the composition. It should be understood that the sum of wt % values for all components in a disclosed composition or formulation are equal to 100.
Unless otherwise stated to the contrary herein, all test standards are the most recent standard in effect at the time of filing this application.
Each of the materials disclosed herein are either commercially available and/or the methods for the production thereof are known to those of skill in the art.
It is understood that the compositions disclosed herein have certain functions. Disclosed herein are certain structural requirements for performing the disclosed functions and it is understood that there are a variety of structures that can perform the same function that are related to the disclosed structures, and that these structures will typically achieve the same result.
With reference to
At the step of applying at least one chemical additive 300 to the fabric, which follows the step of applying a laser treatment 200 to the fabric, the at least one chemical additive can enter the plurality of pores or attach to the pores, which improves the durability of the chemical additive(s) in the fabric; i.e., the chemical additive is retained within the fabric longer during use and laundering.
In some aspects the step of applying a laser treatment 200 to the fabric to form a plurality of pores on fibers of at least the body side of the fabric provides the fabric with an increased surface area as compared to a substantially similar fabric that has not been subjected to a laser treatment. The plurality of pores open up the surface of the fibers, increasing the surface area of the fibers and the fabric including them. In addition, the removal of material from the surface of the fibers reduces contact points of the fabric against the skin of the wearer (assuming the fabric is the inside layer of a garment). The reduced contact points and pores in the fibers provides a microclimate that reduces friction and enhances comfort of the fabric against the skin, as heat and moisture (sweat) generated from a wearer can more easily dissipate from the surface of the skin. Thus, in some aspects the step of applying a laser treatment 200 to the fabric provides the fabric with an enhanced microclimate as compared to a substantially similar fabric that has not been subjected to a laser treatment.
As used herein “substantially similar fabric” means a fabric that includes the same fibers or fiber blends, is the same fabric type (e.g., woven, knit, nonwoven), has the same fabric weight, and includes the same amount and type of chemical additive(s). In other words, the fabric is the same fabric as the fabric according to aspects described herein but it has not been laser-treated to create a plurality of pores on fibers thereof.
In certain aspects the laser treatment 200 is applied to both the body side and the face side of the fabric such that the plurality of pores is located on both the body side and the face side of the fabric.
The fibers of the fabric can be any suitable fiber that, when the laser treatment 200 is applied thereto, will have pores formed thereon. The fibers may be natural fibers, synthetic fibers, or a combination thereof. Purely exemplary natural fibers suitable for use in fabrics of the present disclosure include, but are not limited to, cotton, wool, leather, silk, and combinations thereof. In particular aspects the fibers are cotton or cotton blends. Purely exemplary synthetic fibers suitable for use in fabrics of the present disclosure include, but are not limited to, viscose, polyester, nylon, polypropylene, modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), melamine and combinations thereof.
The step of applying the laser treatment 200 may include using any suitable type of laser to treat the fabric. Exemplary lasers include but are not limited to an yttrium aluminum garnet (YAG) laser and a fiber laser. In some aspects the laser has a narrow beam so that it affects individual fibers of the fabric at a micro or nano level, in contrast to current laser fabric treating technology which has a wide beam and affects entire fibers of the fabric, such as at a macro level. In a particular aspect the laser may have a wavelength of 10.6 μm, although any wavelength suitable for forming a plurality of pores on the fibers may be used. Laser parameters may be adjusted depending on fabric type and other properties. For example, a lower power laser may be desirable for use on fibers such as nylon which could melt when treated with a high power laser.
The at least one chemical additive in the step of applying at least one chemical additive 300 can be any chemical additive that provides desired properties to the fabric. Purely exemplary chemical additives suitable for use in aspects of the disclosure include, but are not limited to, silver (for antimicrobial and/or odor control properties), titanium dioxide (for ultraviolet (UV) protection and moisture transport properties), zinc peroxide (for antistatic properties), aerogels (for thermal insulation) and keratin (for shrink resistance). The step of applying the at least one chemical additive 300 may be performed using any suitable chemical application process. Exemplary processes include but are not limited to spray-coating, pad-dipping, foaming, dyeing, spin coating, powder coating, kiss roll coating, screen printing, digital printing, or any combination of these processes.
The at least one chemical additive may be in the form of nanoparticles 310 (have a particle size in the nanometer (nm) range), microparticles 320 (have a particle size in the micrometer (μm) range) or in the form of larger particles 330 (i.e., macromolecules). If the particles are smaller than the pore size of the fibers the particles can fit within the pores and be embedded within. If the particles are larger than the pore size of the fibers or if they are not within the pores they may be anchored partially within the pores or to the edge of the pores. Embedding of the chemical additive within the pores or anchoring of the chemical additive to the pore improves the durability of the chemical additive in the fabric, as discussed above. It will be recognized that a particular chemical additive may have particles of varying sizes, and that some particles of the chemical additive may be embedded within some pores in the fibers, and that other particles of the chemical additive may be partially anchored within some pores and/or anchored to the edge of some pores.
Exemplary chemical additives suitable for use in aspects of the disclosure include, but are not limited to, cellulose nano crystals (CNC) and cellulose nano filaments (CNF). In one purely nonlimiting example cellulose nano crystals have a nominal average length of 150 nm and a nominal average diameter of 7.5 nm, providing a nominal aspect ratio of 20. One gram of CNC nominally contains over 125 quadrillion (1016) particles, each with a nominal surface area of 4500 nm2, theoretically providing a surface area of about 550 square meters per gram of material. As a result, the CNC has a high degree of interaction with its surroundings.
Cellulose nano filaments are rope-like and have a high aspect ratio with width of approximately 5-60 nm and lengths of 0.5-5 CNFs may also be more flexible as compared to CNCs.
CNCs and CNFs may be useful as chemical additives in the step of applying at least one chemical additive 300 for enhancing textile functional finishing properties. The large surface area of these chemicals can enhance the durability of these additives. In addition, they have high thermal stability, which may provide an improvement in mechanical strength improvement, and they may further contribute to a better hand feel. Both CNC and CNF can be modified to improve their compatibility with various resins used in clear coatings.
Another potential benefit of using CNCs/CNFs is that because they are nano-sized, they can fit within the pores formed during the step of applying a laser treatment 200 to the fabric, which will improve the durability of the CNCs/CNFs in the fabric.
In some aspects the at least one chemical additive may be fixed to the fabric—and particles of the chemical additive embedded within the pores or anchored to the pores—by curing the additive in an optional curing treatment 400. Any suitable process may be applied to the chemical additive to cure it. Exemplary curing treatments include, but are not limited to, laser curing 410 and ultraviolet (UV) curing 420. It will be recognized that certain chemical additives need not be cured, and that other known processes such as drying processes may fix the additive to the fabric.
The optional curing treatment 400 may offer one or more advantages over conventional finishing methods. Curing treatments offer high productivity and can be completed in a matter of seconds, in contrast to conventional methods that can take several minutes or up to an hour. In addition, they are more suited to zonal application of chemical additives to discrete regions of the fabric/garment, which can reduce waste and allow for functional properties only in areas in which the chemical is required. Other potential benefits of curing treatments include, but are not limited to, process consistency, energy savings, and smaller equipment footprint.
In a curing treatment, laser light irradiates a substrate (e.g., a fabric/garment) and generates thermal energy, which is then used to cure the substrate. Methacrylate double bonds are a commonly used functionality for energy-based curing treatments. A photoinitiator may be present in such formulations to absorb the laser light and generate free radicals. The free radicals react with the double bonds, causing a chain reaction and polymerization.
Particular chemical additives may be more useful in certain regions of a fabric, such as chemical additives to provide antimicrobial, odor control and/or moisture transport properties in regions of the fabric that will be proximate a wearer's armpit or crotch. In another example, stain resistance chemical additives may be more useful in regions of the fabric that will be proximate a wearer's shirt collar or shirt cuff. Accordingly, in certain aspects the laser treatment 200 is applied only to discrete regions of the fabric such that the plurality of pores are formed in the discrete regions of the fabric.
In further aspects the method 10 includes applying an optional pretreatment process 500 to the fabric prior to applying the laser treatment 200. Exemplary pretreatment processes 500 include, but are not limited to, mercerization treatments and chemical coating treatments. Mercerization of fabrics, and in particular cotton fabrics, affects various fabric properties. Of note, however, mercerization can cause swelling of the fibers in the fabric and increase the surface area of the fabric. Pretreating a fabric with a mercerization process prior to laser-treating the fabric can thus result in a fabric having an even greater surface area as compared to a fabric that has only been mercerized or only been laser treated. Similarly, chemical coating pretreatments can be applied to the fabric to improve certain fabric processes prior to the laser treatment. For example, a polydimethylsiloxane (PDMS) coating may provide the fabric with hydrophobic properties and improve its water resistance.
In certain aspects a post-wash process 600 may be applied to the laser-treated fabric 100. Exemplary post-wash processes 600 include, but are not limited to, rinsing, enzyme washing, chemical bleaching, applying a softener, ozone color removal treatment and combinations thereof. In one aspect a post-wash process 600 such as rinsing may be particularly desirable to remove ash and/or loose particles that result from the laser treatment 200 and/or the optional curing treatment 400. In another aspect a post-wash process 600 that may be applied to denim fabrics includes an enzyme washing step which removes warp indigo color from the denim and improves the aesthetic appearance of the denim. In a further aspect a post-wash process 600 may include applying a softener, which enhances the hand (feel) of the fabric.
In certain aspects a fabric to which the method 10 described herein has been applied has improved properties as compared to a substantially similar fabric that does not include the plurality of pores on fibers of the fabric. Improved properties may include, but are not limited to, one or more of antibacterial properties, odor control properties, ultraviolet (UV) protection, moisture transport properties, antistatic properties, thermal insulation properties, shrink resistance, abrasion resistance, and stain repellant properties. In particular aspects the at least one chemical additive in the fabric exhibits improved wash fastness as compared to a chemical additive in a substantially similar fabric that does not comprise the plurality of pores.
In some aspects of the disclosure the plurality of pores have a pore size of from about 1 nm to about 20 μm. In certain aspects the plurality of pores have a pore size of from about 20 nm to about 10 μm, or from about 50 nm to about 5 μm, or from about 100 nm to about 2 μm. In particular aspects the plurality of pores have a pore size less than about 20 μm, or less than about 15 μm, or less than about 10 μm, or less than about 5 μm, or less than about 2 μm.
Certain aspects of the disclosure relate to a laser-treated fabric 100 and garments incorporating the laser-treated fabric 100. The fabric 100 has a body side and a face side. The fabric 100 includes a plurality of pores located on at least some fibers on at least the body side of the fabric 100, and at least one chemical additive embedded within or anchored to the plurality of pores. In certain aspects the pores have a pore size of from about 1 nm to about 20 μm.
The plurality of pores are formed by applying a laser treatment to at least the body side of the fabric 100. The laser treatment applied to the fibers of the fabric 100 creates pores in the fibers. The chemical additive(s) can enter the pores or attach to the pore, which improves the durability of the chemical additive(s) in the fabric; i.e., the chemical additive is retained within the fabric longer during use and laundering.
In some aspects the plurality of pores on fibers of at least the body side of the fabric 100 provide the laser-treated fabric with an increased surface area as compared to a substantially similar fabric that has not been subjected to a laser treatment. The plurality of pores open up the surface of the fibers, increasing the surface area of the fibers and the fabric including them. In addition, the removal of material from the surface of the fibers reduces contact points of the fabric against the skin of the wearer (assuming the fabric is the inside layer of a garment). The reduced contact points and pores in the fibers provides a microclimate that reduces friction and enhances comfort of the fabric against the skin, as heat and moisture (sweat) generated from a wearer can more easily dissipate from the surface of the skin. Thus, in some aspects the fabric has an enhanced microclimate as compared to a substantially similar fabric that has not been subjected to a laser treatment.
In certain aspects the laser treatment is applied to both the body side and the face side of the fabric 100 such that the plurality of pores is located on both the body side and the face side of the fabric 100.
The fibers of the fabric 100 can be any suitable fiber that, when laser-treated, will have pores formed thereon. The fibers may be natural fibers, synthetic fibers, or a combination thereof. Purely exemplary fibers include but are not limited to those described above.
In some aspects the plurality of pores have a pore size of from about 1 nm to about 20 μm. In certain aspects the plurality of pores have a pore size of from about 20 nm to about 10 μm, or from about 50 nm to about 5 μm, or from about 100 nm to about 2 μm. In particular aspects the plurality of pores have a pore size less than about 20 μm, or less than about 15 μm, or less than about 10 μm, or less than about 5 μm, or less than about 2 μm.
The at least one chemical additive can be any chemical additive that provides desired properties to the fabric 100. Purely exemplary chemical additives suitable for use in aspects of the disclosure include, but are not limited to, those described above. The at least one chemical additive may be in the form of nanoparticles, microparticles, or in the form of larger particles as described above.
In some aspects the at least one chemical additive may be cured in order to fix the chemical additive within the pores or anchor the chemical additive to the pores. Suitable processes for curing the chemical additive are described above.
In further aspects the fabric may be pretreated prior to application of the laser treatment to the fabric 100. Exemplary pretreatment processes include, but are not limited to, those processes described above.
In certain aspects the laser-treated fabric described herein has improved properties as compared to a substantially similar fabric that does not include the plurality of pores on fibers of the fabric. Improved properties may include, but are not limited to, one or more of antibacterial properties, odor control properties, ultraviolet (UV) protection, moisture transport properties, antistatic properties, thermal insulation properties, shrink resistance, abrasion resistance, and stain repellant properties. In particular aspects the at least one chemical additive in the fabric exhibits improved wash fastness as compared to a chemical additive in a substantially similar fabric that does not comprise the plurality of pores.
Aspects of the disclosure also relate to a garment including a laser-treated fabric. The laser-treated fabric includes a body side and a face side, and includes a plurality of pores located on at least some fibers on at least the body side of the fabric and at least one chemical additive embedded within or anchored to the plurality of pores. In certain aspects the pores have a pore size of from about 1 nm to about 20 μm.
The fabric in the garment may be laser-treated such that the plurality of pores are located in discrete regions of the garment according to aspects described above. In some aspects the garment is a shirt or a jacket and the discrete regions comprise one or more of a shirt collar region, a shirt cuff region or a shirt armpit region. In further aspects the garment is pants and the discrete regions comprise one or more of a knee region or a crotch region.
Various combinations of elements of this disclosure are encompassed by this disclosure, e.g., combinations of elements from dependent claims that depend upon the same independent claim.
In various aspects, the present disclosure pertains to and includes at least the following aspects.
Aspect 1: A laser-treated fabric having a body side and a face side, comprising, consisting of, or consisting essentially of:
a plurality of pores located on at least some fibers on at least the body side of the fabric; and
at least one chemical additive embedded within or anchored to the plurality of pores,
wherein the pores have a pore size of from about 1 nm to about 20 μm.
Aspect 2: The laser-treated fabric according to Aspect 1, wherein the plurality of pores are formed by applying a laser treatment to at least the body side of the fabric.
Aspect 3: The laser-treated fabric according to Aspect 1 or 2, wherein at least the body side of the fabric has an increased surface area as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 4: The laser-treated fabric according to any of Aspects 1 to 3, wherein at least the body side of the fabric has an enhanced microclimate as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 5: The laser-treated fabric according to any of Aspects 1 to 4, wherein the plurality of pores is located on both the body side and the face side of the fabric.
Aspect 6: The laser-treated fabric according to Aspect 5, wherein the plurality of pores on both the body side and the face side of the fabric are formed by applying a laser treatment to both the body side and the face side of the fabric.
Aspect 7: The laser-treated fabric according to any of Aspects 1 to 6, wherein the fibers comprise natural fibers, synthetic fibers, or a combination thereof.
Aspect 8: The laser-treated fabric according to Aspect 7, wherein the natural fibers comprise cotton, wool, leather, silk or a combination thereof.
Aspect 9: The laser-treated fabric according to Aspect 7, wherein the synthetic fibers comprise viscose, polyester, nylon, polypropylene, modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), melamine and combinations thereof.
Aspect 10: The laser-treated fabric according to any of Aspects 1 to 9, wherein the at least one chemical additive is cured.
Aspect 11: The laser-treated fabric according to any of Aspects 1 to 10, wherein the at least one chemical additive comprises silver, titanium dioxide, zinc peroxide, aerogel, keratin or a combination thereof.
Aspect 12: The laser-treated fabric according to any of Aspects 1 to 11, wherein the at least one chemical additive is in the form of nanoparticles, microparticles or macromolecules, and the nanoparticles, microparticles or macromolecules are embedded within or anchored to the plurality of pores.
Aspect 13: The laser-treated fabric according to any of Aspects 1 to 12, wherein the at least one chemical additive is in the form of nanoparticles or microparticles, and the nanoparticles or microparticles are embedded within or anchored to the plurality of pores.
Aspect 14: The laser-treated fabric according to Aspect 12 or 13, wherein the at least one chemical additive comprises cellulose nano crystals (CNC), cellulose nano filaments (CNF) or a combination thereof.
Aspect 15: The laser-treated fabric according to any of Aspects 1 to 14, wherein the fabric has improved properties as compared to a substantially similar fabric that has not been subjected to a laser treatment, wherein the improved properties include one or more of antibacterial properties, odor control properties, ultraviolet (UV) protection, moisture transport properties, antistatic properties, thermal insulation properties, shrink resistance, abrasion resistance, and stain repellant properties.
Aspect 16: The laser-treated fabric according to any of Aspects 1 to 15, wherein the at least one chemical additive in the fabric exhibits improved wash fastness as compared to a chemical additive in a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 17: The laser-treated fabric according to any of Aspects 1 to 16, wherein the plurality of pores are formed by applying a laser treatment to at least the body side of the fabric, and the fabric is pretreated prior to application of the laser treatment.
Aspect 18: The laser-treated fabric according to Aspect 17, wherein the pretreatment is a mercerization treatment or a chemical coating treatment.
Aspect 19: A garment comprising a laser-treated fabric, the laser-treated fabric having a body side and a face side and comprising, consisting of, or consisting essentially of:
a plurality of pores located on at least some fibers on at least the body side of the fabric; and
at least one chemical additive embedded within or anchored to the plurality of pores,
wherein the pores have a pore size of from about 1 nm to about 20 μm.
Aspect 20: The garment according to Aspect 19, wherein the fabric is laser-treated such that the plurality of pores are located in discrete regions of the fabric.
Aspect 21: The garment according to Aspect 19 or 20, wherein the garment is a shirt or a jacket and the discrete regions comprise one or more of a shirt collar region, a shirt cuff region or a shirt armpit region.
Aspect 22: The garment according to Aspect 19 or 20, wherein the garment is pants and the discrete regions comprise one or more of a knee region or a crotch region.
Aspect 23: The garment according to any of Aspects 19 to 22, wherein the plurality of pores are formed by applying a laser treatment to at least the body side of the fabric, and the fabric is pretreated prior to application of the laser treatment.
Aspect 24: The garment according to Aspect 23, wherein the pretreatment is a mercerization treatment or a chemical coating treatment.
Aspect 25: The garment according to any of Aspects 19 to 24, wherein at least the body side of the fabric has an increased surface area as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 26: The garment according to any of Aspects 19 to 25, wherein at least the body side of the fabric has an enhanced microclimate as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 27: The garment according to any of Aspects 19 to 26, wherein the plurality of pores is located on both the body side and the face side of the fabric.
Aspect 28: The garment according to Aspect 27, wherein the plurality of pores on both the body side and the face side of the fabric are formed by applying a laser treatment to both the body side and the face side of the fabric.
Aspect 29: The garment according to any of Aspects 19 to 28, wherein the fibers comprise natural fibers, synthetic fibers, or a combination thereof.
Aspect 30: The garment according to Aspect 29, wherein the natural fibers comprise cotton, wool, leather, silk or a combination thereof.
Aspect 31: The garment according to Aspect 29, wherein the synthetic fibers comprise viscose, polyester, nylon, polypropylene, modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), melamine and combinations thereof.
Aspect 32: The garment according to any of Aspects 19 to 31, wherein the at least one chemical additive is cured.
Aspect 33: The garment according to any of Aspects 19 to 32, wherein the at least one chemical additive comprises silver, titanium dioxide, zinc peroxide, aerogel, keratin or a combination thereof.
Aspect 34: The garment according to any of Aspects 19 to 33, wherein the at least one chemical additive is in the form of nanoparticles, microparticles or macromolecules, and the nanoparticles, microparticles or macromolecules are embedded within or anchored to the plurality of pores.
Aspect 35: The garment according to any of Aspects 19 to 34, wherein the at least one chemical additive is in the form of nanoparticles or microparticles, and the nanoparticles or microparticles are embedded within or anchored to the plurality of pores.
Aspect 36: The garment according to Aspect 34 or 35, wherein the at least one chemical additive comprises cellulose nano crystals (CNC), cellulose nano filaments (CNF) or a combination thereof.
Aspect 37: The garment according to any of Aspects 19 to 36, wherein the fabric has improved properties as compared to a substantially similar fabric that has not been subjected to a laser treatment, wherein the improved properties include one or more of antibacterial properties, odor control properties, ultraviolet (UV) protection, moisture transport properties, antistatic properties, thermal insulation properties, shrink resistance, abrasion resistance, and stain repellant properties.
Aspect 38: The garment according to any of Aspects 19 to 37, wherein the at least one chemical additive in the fabric exhibits improved wash fastness as compared to a chemical additive in a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 39: A method for treating a fabric, the fabric having a body side and a face side, the method comprising, consisting of, or consisting essentially of:
applying a laser treatment to at least the body side of the fabric to form a plurality of pores on fibers of at least the body side of the fabric; and
applying at least one chemical additive to the fabric such that the at least one chemical additive is embedded within or anchored to the plurality of pores,
wherein the pores have a pore size of from about 1 nm to about 20 μm.
Aspect 40: The method according to Aspect 39, further comprising applying a curing treatment to the fabric to cure the at least one chemical additive.
Aspect 41: The method according to Aspect 40, wherein the curing treatment is an additional laser treatment or a heat treatment.
Aspect 42: The method according to any of Aspects 39 to 41, wherein the laser treatment is applied to both the body side and the face side of the fabric.
Aspect 43: The method according to any of Aspects 39 to 42, wherein the laser treatment is applied to the fabric using a laser having a wavelength of about 10.6 μm.
Aspect 44: The method according to any of Aspects 39 to 43, wherein the laser treatment is applied to discrete regions of the fabric such that the plurality of pores are formed in only the discrete regions of the fabric.
Aspect 45: The method according to any of Aspects 39 to 44, further comprising pretreating the fabric prior to applying the laser treatment to the fabric.
Aspect 46: The method according to Aspect 45, wherein the pretreatment is a mercerization treatment or a chemical coating treatment.
Aspect 47: The method according to any of Aspects 39 to 46, wherein at least the body side of the fabric has an increased surface area as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 48: The method according to any of Aspects 39 to 47, wherein at least the body side of the fabric has an enhanced microclimate as compared to a substantially similar fabric that has not been subjected to a laser treatment.
Aspect 49: The method according to any of Aspects 39 to 48, wherein the fibers comprise natural fibers, synthetic fibers, or a combination thereof.
Aspect 50: The method according to Aspect 49, wherein the natural fibers comprise cotton, wool, leather, silk or a combination thereof.
Aspect 51: The method according to Aspect 49, wherein the synthetic fibers comprise viscose, polyester, nylon, polypropylene, modacrylic, aramid, polybenzimidazole (PBI), polybenzoxazole (PBO), melamine and combinations thereof.
Aspect 52: The method according to any of Aspects 39 to 51, further comprising curing the at least one chemical additive to embed the at least one chemical additive within the plurality of pores or anchor the at least one chemical additive to the plurality of pores.
Aspect 53: The method according to any of Aspects 39 to 52, wherein the at least one chemical additive comprises silver, titanium dioxide, zinc peroxide, aerogel, keratin or a combination thereof.
Aspect 54: The method according to any of Aspects 39 to 53, wherein the at least one chemical additive is in the form of nanoparticles, microparticles or macromolecules, and the nanoparticles, microparticles or macromolecules are embedded within or anchored to the plurality of pores.
Aspect 55: The method according to any of Aspects 39 to 54, wherein the at least one chemical additive is in the form of nanoparticles or microparticles, and the nanoparticles or microparticles are embedded within or anchored to the plurality of pores.
Aspect 56: The garment according to Aspect 54 or 55 wherein the at least one chemical additive comprises cellulose nano crystals (CNC), cellulose nano filaments (CNF) or a combination thereof.
Aspect 57: The method according to any of Aspects 39 to 56, wherein the fabric has improved properties as compared to a substantially similar fabric that has not been subjected to a laser treatment, wherein the improved properties include one or more of antibacterial properties, odor control properties, ultraviolet (UV) protection, moisture transport properties, antistatic properties, thermal insulation properties, shrink resistance, abrasion resistance, and stain repellant properties.
Aspect 58: The method according to any of Aspects 39 to 57, wherein the at least one chemical additive in the fabric exhibits improved wash fastness as compared to a chemical additive in a substantially similar that has not been subjected to a laser treatment.
Aspect 59: A garment comprising a fabric treated according to the method of any of Aspects 39 to 58.
Aspect 60: The garment according to Aspect 59, wherein the fabric comprises the plurality of pores in only discrete regions of the fabric.
Aspect 61: The garment according to Aspect 60, wherein the garment is a shirt or a jacket and the discrete regions comprise one or more of a shirt collar region, a shirt cuff region or a shirt armpit region.
Aspect 62: The garment according to Aspect 60, wherein the garment is pants and the discrete regions comprise one or more of a knee region or a crotch region.
The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how the compounds, compositions, articles, devices and/or methods claimed herein are made and evaluated, and are intended to be purely exemplary and are not intended to limit the disclosure. Efforts have been made to ensure accuracy with respect to numbers (e.g., amounts, temperature, etc.), but some errors and deviations should be accounted for. Unless indicated otherwise, parts are parts by weight, temperature is in ° C. or is at ambient temperature, and pressure is at or near atmospheric. Unless indicated otherwise, percentages referring to composition are in terms of wt %.
There are numerous variations and combinations of reaction conditions, e.g., component concentrations, desired solvents, solvent mixtures, temperatures, pressures and other reaction ranges and conditions that can be used to optimize the product purity and yield obtained from the described process. Only reasonable and routine experimentation will be required to optimize such process conditions.
A cotton weft fabric at 250× and 1000× magnification is illustrated in
Fibers on the body side of a denim fabric were treated with a 2500 watt (W) carbon dioxide (CO2) laser from LasX. The laser had a wavelength of 10.6 μm. As shown in
A polydimethylsiloxane (PDMS) coating was applied to a denim fabric. Fibers on the body side of the PDMS-coated fabric were then treated with a 2500 W CO2 laser from LasX. The laser had a wavelength of 10.6 μm. Pores were not readily apparent in the fabric (see
Fibers on the body side of a prewashed denim fabric were treated with a 2500 W CO2 laser from LasX. The laser had a wavelength of 10.6 μm. As shown in
A polydimethylsiloxane (PDMS) coating was applied to a denim fabric. Fibers on the body side of the PDMS-coated fabric were then treated with a 2500 W CO2 laser from LasX. The laser had a wavelength of 10.6 μm. Pores were not readily apparent in the fabric (see
The fabric of Example 3A and the fabric of Example 5A are shown in
Prewashed (1-hour stone enzyme wash) and unwashed (rigid) 100% denim fabrics were subjected to a laser treatment step on both the front side and the back side of the fabric. The front side of each fabric was the blue warp side; the back side of each fabric was the white fill side. The influence of varying degrees of laser intensity (low, medium and high) and beam diameter (low, medium and high) on pore size and pore density was evaluated. The laser applied to the samples was a 2500 watt (W) laser. All laser-treated samples were rinsed in water for about 10 minutes to remove ash (laser burnt spots).
Scanning electron microscope (SEM) images of exemplary samples are shown in
From the images it is evident that the unwashed/rigid denim had more pores than the washed denim, and the pores were smaller in size (average diameter <3 micrometer (μm)). Washed denim generally tends to have yarns of larger yarn diameter as a result of longer exposure to warm/hot conditions, caustic washings, etc., which can lead to some amount of fiber swelling and a higher yarn surface area; as a result the pore size of the washed denim appeared to be larger (average diameter <4 μm).
Overall, the pore size ranged from <1 μm to about 20 μm. For rigid denim, a linear trend was observed in that average pore size increased with increased laser power at all tested beam diameters—SEM images for 1.2 mm beam diameter are shown but the same trend was observed for a beam diameter of 0.75 mm. For washed denim, there was no trend observed with respect to average pore size and laser power, although it was observed that as beam diameter was increased (e.g., to 1.2 mm) larger pores were formed than at lower beam diameters (e.g., 0.75 mm). Further, it was observed that denim treated at a lower beam diameter (e.g., 0.75 mm) had a higher number of pores than at a higher beam diameter (e.g., 1.2 mm). A substantial difference in performance/results between warp and fill yarns was not observed, although it is noted that it was difficult to exclude specific yarns (e.g., warp or fill) while imaging them at higher resolutions.
Curing treatments using acrylated chemistry to cure the chemical additive(s) described herein were evaluated. Several formulations of energy-curable formulations based on acrylated resin monomers and oligomers (mono, di, tri and tetra functional) were considered. The resins were tested with and without additives (such as with varying concentrations of photoinitiator) and at varying viscosities.
Concentrated and diluted resin formulations were applied onto prewashed denim samples with spraying, stamping, blades and/or screen printing methods. Organic solvents were used to dilute the resins. The influence of a range of laser operating conditions (intensity, speed, number of passes, etc.) on curing was studied. Multiple passes of a laser beam were applied over the laser surface to cure the chemical additive. Fine-tuning of laser settings was achieved to provide complete curing of chemistry. In this example, rapid curing was observed at pass #20, which suggests a residual buildup of heat followed by rapid free radical reaction and polymerization.
From the results, it was apparent that the curing performance was affected by a combination of various factors, including but not necessarily limited to the chemical formulation, the application method and the laser energy. It was thus possible to optimize laser curing properties and parameters to result in complete polymerization. Modifications included using different concentrations of benzoyl peroxide photoinitiator additive and monofunctional/trifunctional monomer and oligomer to improve the flexibility or hand feel of the coatings. Other fabric/garment properties that may be improved by modifying the factors described herein include, but are not limited to, tear resistance, abrasion resistance, coating transparency, coating weight, fabric color change, breathability, and a combination thereof.
Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.
The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
The present application claims the benefit of U.S. Provisional Patent Application No. 62/435,015 filed Dec. 15, 2016, the disclosure of which is incorporated herein by this reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62435015 | Dec 2016 | US |
